Wire reel blank

ABSTRACT

A one-piece reel blank comprising a single piece of cardboard material, or other relatively rigid but foldable thin sheet material, which is cut to form a center panel, a pair of wall panels joined, and a pair of flaps. The center panel is preferably generally rectangular in shape with a pair of first fold lines and a pair of first lateral edges. The wall panels are respectively joined to opposite longitudinal sides of the center panel along substantially parallel second fold lines. Each second fold line has a length that is preferably less than that of the first fold line. A flap is joined to an adjacent wall panel along a third fold line opposite a fold line and substantially parallel thereto. Each flap is generally rectangular in shape and has a longitudinal fourth fold line having a central perforated or scored portion joining slit end portions, respectively terminating at lateral edges. Preferably, the flaps are positionable in overlapping relationship along their longitudinal edges for cooperation to define a second center panel coextensive to the center panel.

BACKGROUND

[0001] This application relates generally to a reel for storing and dispensing wire or cable or other continuous coiled material. More particularly, this application relates to a one-piece reel blank which is adapted to be folded into a reel.

[0002] Various types of reels have been developed over the years in order to store and dispense wire or cable. These reels have been typically made of metal, plastic or wooden materials, so as to better support the wire or cable and to withstand abuse resulting from the transportation of the reels. While these prior reels generally worked for their intended purposes, there are several drawbacks associated with their use.

[0003] One such drawback is that the costs of manufacture and of materials used are significant. A new reel is typically included for each length of wire sold or made, and distributors and manufacturers of wire and cable usually do not reclaim reels after its use. Consequently, for a distributor of wire or cable, the cost of a reel is a significant expense.

[0004] Another drawback is the space that such reels occupy. Storage of such reels may pose a problem to some. The bigger the reel the more space it consumes. If required in large numbers, as are needed by some, reels can occupy a significant amount of storage space.

[0005] In order to avoid the above, reels have been devised from cardboard blanks. These cardboard blanks can come as single-sheet blanks or some may come as multiple blank sheets which must be connected together. These blanks typically come in a flattened state which requires relatively little storage space, and they are typically assembled just prior to their use. While being significantly cheaper and easier to store than their metal or plastic counterparts, prior cardboard reels also have their own drawbacks.

[0006] The corrugated cardboard material, of which prior reels are typically made, is significantly weaker than their wooden or metal counterparts. Reels are commonly jostled about in use or transportation, and many cardboard reels are just not durable enough to withstand this duress. A single sheet of cardboard is also typically not strong enough to physically support large quantities of wire and cable.

[0007] Also, many cardboard blank reels can be quite difficult to construct. There are some cardboard blank reels which require folding several sheets and attaching the sheets together. The extra effort to construct such cardboard blank reels sometimes offsets their benefits.

[0008] Furthermore, although most non-cardboard reels are adapted to be dispersed from a reel carrier, such as a shaft or axle, many cardboard reels are not. Resulting partly from the strength and durability problems of these cardboard reels, and also partly from their design, many of the existing cardboard reels are incapable of being utilized with a reel carrier or dispenser.

SUMMARY

[0009] Therefore, it is a general object of this application to provide a blank made of corrugated cardboard, or other relatively stiff but foldable material, that avoids the disadvantages of prior designs, while affording additional structural and operating advantages.

[0010] An important feature is the provision of a one-piece reel blank which is of simple construction and relatively inexpensive.

[0011] Another important feature is the provision of a one-piece reel blank with sufficient strength and durability to support and transport large quantities of wire or cable.

[0012] Another important feature is the provision of a one-piece reel blank which requires little storage space prior to use.

[0013] Another important feature is the provision of a one-piece reel blank which is adapted to dispense wire or cable from a reel dispenser.

[0014] A further feature is the provision of a one-piece reel blank which is easily constructed to form a reel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] For the purpose of facilitating an understanding of the subject matter sought to be protected, there is illustrated in the accompanying drawings an embodiment thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.

[0016]FIG. 1 is a plan review of an embodiment of one-piece reel blank.

[0017]FIG. 2 is a perspective view of the one-piece reel blank of FIG. 1 positioned in a first state of construction.

[0018]FIG. 3 is a perspective view of the one-piece reel blank of FIG. 1 positioned in a second state of construction.

[0019]FIG. 3a is a perspective view of the one-piece reel blank of FIG. 1 positioned in a third state of construction.

[0020]FIG. 4 is a perspective view of the one-piece reel blank of FIG. 1 positioned in a fourth state of construction through the use of an assembly jig.

[0021]FIG. 5 is a plan review of an alternate embodiment of a one-piece reel blank.

[0022]FIG. 5a an enlarged, fragmentary, perspective view of the alternative embodiment of the one-piece reel blank in a fourth state of construction.

[0023]FIG. 6 is a perspective view of the one-piece reel blank of FIG. 1 in a fully constructed state.

[0024]FIG. 7 is a perspective view of the fully constructed reel of FIG. 6 attached to a reel carrier.

DETAILED DESCRIPTION

[0025] Referring to FIG. 1, there is shown an embodiment of one-piece reel blank 10 comprising a single piece of cardboard material which is cut to form a center panel 11, a pair of wall panels 12 joined, and a pair of flaps 13. The reel blank 10 is preferably formed of corrugated cardboard, or other relatively rigid but foldable thin sheet material like plastic, but the reel blank may also comprise multiple discrete sheets of material.

[0026] The center panel 11 is preferably generally rectangular in shape with a pair of first fold lines 14 and a pair of first lateral edges 15. The first fold lines 14 extend longitudinally along the center panel 11 substantially parallel to each other, and each includes slitted portions 16, respectively extending from first lateral edges 15, and a perforated portion 17 connecting the slitted portions 16. Confronting slitted portions 16 cooperate with a central portion of the adjacent first lateral edge 15 to define a first tongue 18 foldable to a nonparallel position with respect to the center panel 11 along a fold line 18 a. The center panel 11 may also have a pair of generally parallel fold lines 15 a extending laterally between the first fold lines 14.

[0027] The wall panels 12 are respectively joined to opposite longitudinal sides of the center panel 11 along substantially parallel second fold lines 19. Each second fold line 19 has a length that is preferably less than that of the first fold lines 14.

[0028] The center panel 11 may also include angled slits 20 extending generally laterally from each end of a respective second fold line 19 to an adjacent end of a correspondent fold line 15 a. The slits 20 cooperate with the slitted portions 16 of the first fold lines 14 to define four second tongues 21, each being foldable along a first fold line 14 to a nonparallel position with respect to the center panel 11.

[0029] The wall panels 12 are preferably identically-shaped and sized. While octagonal shapes are illustrated, other shapes could be used. Circular apertures 12 a respectively extend through the wall panels 12 centrally thereof. Various other apertures can be cut out from the wall panels 12 to accommodate various reel carriers, to receive end portions of wire or cable coils, or to accommodate other items used with the one-piece reel blank, such as assembly jigs or fixtures.

[0030] Each flap 13 is joined to an adjacent wall panel 12 along a third fold line 22 opposite a fold line 19 and substantially parallel thereto. Each flap 13 is generally rectangular in shape and has a longitudinal fourth fold line 23 having a central perforated or scored portion 24 joining slit end portions 25, respectively terminating at lateral edges 26. Each flat 13 also has lateral fold lines 27 substantially perpendicular to the fold line 24 and terminating at a distal longitudinal edge 28. Each flap 13 may also include second angled slits 30 extending generally laterally from each end of a respective third fold line 22 to the inner end of a fold line 27 for cooperation with the slit end portions 25 to define respective third tongues 31 foldable along the fourth fold line 23 to a nonparallel position with respect to their respective flap 13.

[0031] Preferably, the flaps 13 are positionable in overlapping relationship along their longitudinal edges 28 for cooperation to define a second center panel 25, shown in FIG. 2, coextensive to the center panel 11. Each fold line 27 is generally collinear with a fold line 15 a on the center panel 11 before folding.

[0032] Referring to FIG. 2, in forming a reel, the reel blank 10 is first folded along each second fold line 19 to position the wall panels 12 roughly perpendicular to the center panel 11. In this position, the wall panels 12 are in substantially congruent relationship. Each flap 13 is then folded along the associated third fold line 22 to a position relatively perpendicular to the wall panel 12 and relatively parallel to the center panel 11. In this position, the flaps 13 overlap each other along their longitudinal edges 27 to define a second center panel 25 substantially congruent with the center panel 11. The flaps 13 are preferably adhered to each other in this position by suitable means so that the reel blank 10 then forms a relatively rectangular structure.

[0033] Referring to FIG. 3, the center panel 11 and second center panel 25 are each folded inwardly along the first and fourth fold lines 14, 23 so that each forms a relatively U-shaped, outwardly opening structure located between the wall panels 12, which are now closer together.

[0034] Referring to FIGS. 3A and 4, the center and second center panels 11, 25 are then folded along the fold lines 15 a, 27 to enable the first and second lateral edges 15, 26 of the center and second center panels 11, 25 to be attached together to form a center of the reel. As the lateral edges are brought together, the tongues 21 overlap the inner surface of one of the wall panels 12 and the tongues 31 overlap the inner surface of the other wall panel 12 to provide support to the wall panels 12. The first and second lateral edges may be secured together in any known manner or else maybe left unsecured to be kept together by the cable or wire wound therearound.

[0035] Referring to FIG. 5 and 5 a, in one embodiment the center panel includes a flange 32 extending from each respective lateral edge of the tongues 18, and wherein each flap 13 includes a notch 33 adjacent to each respective second lateral edge 26 and longitudinal edge 28. In this embodiment, the tongues 18 are folded along fold lines 18a and flaps 13 are folded along fold lines 34. The first and second lateral edges 15, 26 are secured to each other by inserting the flanges 32 within the notches 33.

[0036] The reel blank 10 can be assembled by hand without any mechanical assistance, or it can be adapted so that it can be formed with the aid of a jig, as shown in FIGS. 3 and 4. Also, the reel blank can be further adapted to be formed by an automated carton erector apparatus.

[0037] Referring to FIGS. 6 and 7, when formed, the reel blank is capable of carrying and distributing large quantities of wire or cable. The tongues 21, 31 provide a second layer of material to support the wall panels 12 providing needed rigidity to withstand the abuse of travel and use. The octagonal shape of the formed reel also enables it to be self -supporting when laid in both a lateral or longitudinal orientation.

[0038] The reel blank 10 is also adaptable to enable it to be utilized in conjunction with a reel carrier. In the illustrated embodiments, coaxially aligned apertures 12 a communicate with opposite ends of a hollow hub- formed by the center panels 11, 25 to define a passage to receive an axle or shaft of an associated reel carrier. Other apertures can also be added to each wall panel 12 to enable the formed reel to adapt to most reel carrier configurations.

[0039] The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art. 

I claim:
 1. A one-piece reel blank comprising: a first center panel having opposite lateral edges and including a pair of first fold lines extending longitudinally along the center panel between the lateral edges, each first fold line including slitted portions extending respectively from the lateral edges and a perforated portion connecting the slitted portions, slitted portions cooperating at each lateral edge to define a tongue foldable to a nonparallel position with respect to the center panel; a pair of wall panels respectively joined to the opposite side edges of the center panel along longitudinal second fold lines each having a length less than that of the first fold lines; and two flaps respectively joined to the wall panels along longitudinal third fold lines each being generally parallel to and of equal length with the second fold line of the associated wall panel, each flap having a fourth fold line extending longitudinally thereacross and having slitted portions joined by a perforated portion, the flaps defining edges of the blank which are overlappable in use to define a second center panel opposite the first center panel.
 2. The one-piece reel blank of claim 1, wherein each wall panel has an aperture extending therethrough centrally thereof.
 3. The one-piece reel blank of claim 2, wherein the center panel includes slits extending laterally from each end of a respective second fold line to an adjacent first fold line to define respective second tongues foldable along the first fold line to a nonparallel position with respect to the center panel.
 4. The one-piece reel blank of claim 3, wherein each flap includes slits extending laterally from each end of a respective third fold line to an adjacent fourth fold line to define respective third tongues foldable along the fourth fold line to a nonparallel position with respect to their respective flap.
 5. The one-piece reel blank of claim 4, wherein the center panel has a pair of fifth fold lines extending laterally between the first fold lines.
 6. The one-piece reel blank of claim 5, wherein each flap has a pair of generally parallel sixth fold lines, each sixth fold line being generally collinear with a fifth fold line and extending laterally between the fourth fold line and a longitudinal edge of its respective flap opposite the third fold line.
 7. The one-piece reel blank of claim 6, wherein the wall panels are generally polygonal.
 8. The one-piece reel blank of claim 7, wherein the center panel is generally rectangular.
 9. The one-piece reel blank of claim 8, wherein the center panel includes a flange extending from each respective lateral edge, and wherein each flap includes a pair of notches adjacent to a respective second lateral edge.
 10. A one-piece blank adapted to form a reel dispenser comprising: a generally rectangular center panel including a pair of first fold lines extending longitudinally along the center panel, the center panel foldable along the first longitudinal fold lines to define a generally U-shaped cross section; a pair of wall panels respectively joined to opposite side edges of the center panel along second fold lines, each wall panel having an aperture extending therethrough centrally thereof; and two generally rectangular flaps respectively joined to the wall panels along longitudinal third fold lines and each having a distal lateral edge and including a longitudinal fourth fold line, each third fold line being generally parallel to and coextensive to each second fold line, the flaps overlappable in a longitudinal manner to define a second center panel coextensive with the center panel.
 11. The one-piece reel blank of claim 2, wherein the center panel includes slits extending laterally from each end of a respective second fold line to an adjacent first fold line to define respective second tongues foldable along the first fold line to a nonparallel position with respect to the center panel.
 12. The one-piece reel blank of claim 3, wherein each flap includes slits extending laterally from each end of a respective third fold line to an adjacent fourth fold line to define respective third tongues, each third tongue foldable along the associated fourth fold line to a nonparallel position with respect to the associated flap.
 13. The one-piece reel blank of claim 4, wherein the center panel has a pair of generally parallel fifth fold lines extending laterally between the first fold lines.
 14. The one-piece reel blank of claim 5, wherein each flap has a pair of generally parallel sixth fold lines, each sixth fold line being generally collinear with a fifth fold line and extending laterally between the fourth fold line and a longitudinal edge of its respective flap opposite the third fold line.
 15. A method of forming a reel from a one-piece reel blank comprising a first center panel including a pair of longitudinal first fold lines, a pair of first lateral fold lines, and a first pair of lateral edges; a pair of wall panels, each having an aperture therethrough and respectively joined to the center panel along second longitudinal fold lines; and a pair of flaps, each joined to a respective wall panel, opposite the center panel, along a longitudinal third fold, each flap including a longitudinal fourth fold line, a pair of second lateral fold lines, and a second lateral edge; the method comprising: folding the reel blank along its second fold lines to position the wall panels parallel to each other; folding the reel blank along its third longitudinal fold lines; attaching the flaps to each other in overlapping manner to define a second center panel opposite the first center panel; folding the first center panel and the second center panel along the first and fourth fold lines to form a U-shaped cross section in each; and folding the first center panel and the second center panel along the first and second lateral fold lines to enable the first and second lateral edges of the center panel and the overlapped flaps to join together.
 16. The method of claim 15, wherein the center panel includes a lateral edge with a flange portion and wherein the flaps, when overlapped, define a notch, and further comprising the additional step of securing the flange position to the notch.
 17. The method of claim 15, and further comprising the additional step of attaching a reel carrier to the apertures extending through the wall panels. 